CA2062966C

CA2062966C - Method of preparing a frozen yeast dough product

Info

Publication number: CA2062966C
Application number: CA002062966A
Authority: CA
Inventors: Peter Larsen
Original assignee: Kval Marketing Inc
Current assignee: Kval Marketing Inc
Priority date: 1989-07-14
Filing date: 1990-07-11
Publication date: 1999-04-06
Anticipated expiration: 2010-07-11
Also published as: DK348989D0; US5589207A; WO1991001088A1; ATE99870T1; CA2062966A1; NO302552B1; AU6175090A; AU644810B2; NO920182L; EP0482105A1; DE69006031T2; EP0482105B1; NO920182D0; DK0482105T3; DE69006031D1

Abstract

Leavened yeast dough products obtain a long durability in a frozen condition by omitting using in the preparation thereof fermentable carbon hydrates, but the formation in situ of such fermentable carbo n hydrates satisfactory to leaven the dough is ensured by adding one or more amylases to the dough. Upon freezing the activity of the amylase ceases and the concentration of fermentable carbon hydrates falls to such a low value that the proteinase formin g activity of the yeast actually ceases. A possibly desired brown-colouring of the baked product may be ensured by the addition of a mylases with an activity at a relatively high temperature.

Description

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wos1/010~ PCT/DK90tO0l83 , .

A method of preparing a frozen yeast dough product, The invention relates to a method of preparing a frozen yeast dough product in which the dough is pre-pared from flour, water and yeast and one or more amy-lases and possibly other conventional dough lngredi-ents.
For obvious reasons there is a need for a levened yeast dough product that may be marketed when frozen and having a long shelf life in such a condition and which by retailers, restaurants, caf~s etc. or by the consumers themselves may be baked without preceding thawing out and leavening to obtain a pastry having a look and organoleptic properties corresponding to those obtained by conventional baking methods, in which the baking is effected immediately after the dough has risen without any intermediary freezing of the dough.
A long series of experiments has been carried out to fulfil said need. However, it has turned out to be particularly difficult to obtain satisfactory results if the dough product to be frozen contain yeast, and particularly if said yeast when the freezing is performed has a high activity level which is the case with a leavened dough.
2s It has actually turned out that such yeast dough products when consisting of the hitherto used ingre-dients only stand storing when frozen for no more than a few months, and generally for a considerably shorter time, because they will then have been imparted such structual or textural changes that no commercially acceptable product will be obtained by baking.
various methods have been suggested of increas-ing the shelf life of frozen dough products in general.
Thus, US patent No. 4 847 104 suggests using flour with more than 16% of wheat protein, calculated on the totaI
flour content of the dough. It is stated that such a REpl ~Gr~ TsH~l , . ~. . .
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~6~9~6 2 proteln content may provide for obtaining a shelf life also of leavened, frozen yeast dough products for at least 16 weeks. However, the use of flour mixtures of selected types, particularly rich in proteins or with the addition of particularly gluten-containing pro-ducts, entails an increase of the costs and implies certain restrictions with respect to the organoleptic properties of the flnal products. Moreover, the impro-vement of the stability obtained even by large quan-tities of proteins, as demonstrated in the Example ofthe patent specification, is insuffient in connection with leavened yeast dough products.
Other methods have been suggested for the res-triction of the undesired structural change, dough pro-ducts are being subjected to by freezing and cold stor-age. Thus, FR patent No. 2 481 072 deals with practis-ing special temperatures for the rising combined with very low freezing temperatures between -180~C and -l00~C. Such a low freezing temperature only offers satisfactory results, provided the following storing be effected at temperatures lower than those practically coming into consideration.
US patents Nos 4 374 151 and 4 406 911 suggest adding to the dough to be frozen considerable quan-tities of melting polnt lowering agents and hydrophilecolloids, film-forming proteins and surfactants. Such additions are particularly effected with the view of obtaining a good rising in connection with the first part of the baking "oven spring", and the results stated in said references do not reflect-any par-ticularly long durability of the frozen products.
It has been proposed to apply different enzymes in the preparation of dough to change the properties of the final products in a desired direction. It has for example been proposed to apply amylases in amounts of from less than 1 g to some few grams per 100 kg flour REPIACEMENTSHEEl - ': . ...................................... . -.. . .

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in order to obtain a darker crust and to increase the amount of fermentable carbon hydrates in frozen dough products to obtain a more effective proving thereof after thawing. The use of enzymes in yeast dough to be sub~ected to rising followed by freezing has not been suagested.
It has now turned out that a leavened yeast dough product havlng a longer durability when frozen than what applies to prior art leavened frozen yeast dough products may be obtained by a method which according to the invention is characterized in that any fermentable carbon hydrates which would conventionally be used in the preparation of the dough, are replaced by at least one amylase in an amount which by the lS decomposition of starch available in the flour generates fermentable carbon hydrate in a concentration sufflcient to ensure the leavening of the dough product and which is substantially inactive at temperatures below 0~C, and in that the dough product after forming is made to rise and subesequently subjected to freezing.
The term amylase is in this respect used for enzymes which in suitable circumstances decompose gelatinized or ~ech~nically degraded starch by the generation of considerable amounts of fermentable car-bon hydrates, said enzymes comprising both a- and ~-amylases and amyloglucosides. -The invention is not restricted by any theory asto the reason why a frozen product with a very high durability is obtained by the method just described. It is, however, supposed that the predominant reason why conventional yeast dough products after rising only ha~e a short durability when frozen consists in that the protelnases of the yeast decompose the structure or texture forming proteinaceus substances, in par-ticular gluten, also at temperatures at which frozen ' ~'.
- RE~lACEMENT~iHEET
' WO91/01088 PCT/DK90/00183 _ ~ Jj~ 6 6 food products are generally stored, i.e. between -18~C
and -2S~C, but that this activity is particularly effi-cient when fermentable sorts of sugar are available for the yeast ln a certain amount. However, when the amount of fermentable carbon hydrates is below a certain level, the activlty of the yeast at the temperatures in question is so low that the yeast will not form con-siderable amounts of extracellular proteinase attacking the gluten.
By omltting the addition of fermentable carbon hydrate, e.g. in the form of saccharose, glucose or maltose (available in malt flour or in malt extract), by the method according to the invention, but by adding instead amylase, there is formed fermentable carbon hydrate in the dough in an amount sufficient to ensure a yeast activity satisfactory to obtain the desired leavening, but these fermentable carbon hydrates formed by the amylase are consumed approximately at the same rate as formed, and when the leavened yeast product is frozen the activity of the amylase ceases, following which there will be no substantial amounts of fermen-table carbon hydrate available in the dough, thereby causing the activity of the yeast cells to almost cease so that they only to a very small degree liberate glu-ten decomposing proteinases.
Yeast dough products produced by the methodaccording to the invention have been stored in frozen condition for more than one year, but nevertheless after baking they resulted in products, particularly of the Danish pastry type, that were commercially accept-able. Professionals have hitherto taken for impossible to obtain such a long freeze preservation for leavened yeast dough products.
Amylases of the type coming into consideration 3s with respect to the method according to the invention are preferably of a fungal origin. Such amylases are REPIACEMENTSHEET

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wosl/olo88 2 ~ ~ 2 ~ 6 6 PCT/DK90/00183 s commerclally available with activity within various ranges of temperatures and with different thermo-stability .
If an amylase is used that is inactivated at temperatures exceeding 50 to 55~C which applies to a number of commercially available amylase products, active yeast wlll be present in the dough until the formation of the amylase of fermentable carbon hydrate ceases during the first part of the baking and said fermentable carbon hydrate will therefore to a substan-tial degree be consumed by the yeast and the amount present in the dough upon reaching the temperatures at which the formation of a coloured crust takes place will be very small.
In view of the fact that the formation of a satisfactorily brownish crust requires the presence of monosaccharides or reducing disaccharldes participating in a Maillard-reaction the crust will in such cases, as regards certain products, appear too pale and the invention therefore further relates to an embodiment of the above process for the preparation of a yeast pro-duct which upon baking assumes a desired brown-colourlng, said embodlment being characterized by adding the dough preparation an amylase enzyme pre-serving its activity for the decomposition of starch tofermenta~le carbon hydrates at temperatures above 55~C, but which becomes inactive at temperatures above ~0 to 85-C.
The latter feature, i.e. the enzyme is to be actlvated at temperatures exceeding 80 to 85~C, is essential, since no r~Aining enzymatic activity is desired in the final baked product. However, even if some enzymatlc activlty should be present in the baked product this is not regarded as involving any health .. risk.
The flnal product thus has a "natural" com-positlon without the addition of chemical preser-REPI~CEMENTSHEE

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W091/01088 ' PCT/DK90/0018~
2966 ~~' vatives, contrary to what applies to the products obtained by certain of the above described prior methods.
The method according to the invention has been tested, ln particular ln connection with the prepara-tion of Danish pastry, croissants and the like, and extremely good results have been obtained by a method incorporating instead of fermentable carbon hydrates, an amylase that becomes inactive by heating to 55 to 60'C and, together with an amylase which is an amy-loglucosidase that becomes inactive only at 80 to 85~C.
The amounts of enzymes to be used obviously vary, lnter alia in dependence on their activity. Tests reflect that the amylase which becomes inactive at 55 to 60-C is to be used in an amount of at least 3soo SKB units per kg of flour and the amylogucosidase in an amount of at least 60 AG~ per kg of flour. The unit SXB, an abbreviation of Sandstedt, Kneen and Blish, corresponds to 1/35 FAU (Fungal Amylase Unit) and is deterr~ned by comparing with an enzyme standard. The unit AGU is defined as the amount of enzyme whic~
hydrolyzes 1 micro-mol maltose for a half hour at pH
4.3 and 25~C.
A series of satisfactory experiments has been carried out by incorporating in the dough product the enzyme "Fungamyl" R MG 35000 together with the enzyme AMG 300 MG. Both of said enzymes are marketed by Novo-Nordisk, Copenhagen, ~ rk. Fungamyl is declared to be active up to 5S to 60-C, while AMG is active up to 80 to 85~C, i.e. at a temperature exceeding the tem-perature at which a gelatinization of the starch of the flour sets in. Due to the fact that the gelatinized starch is easily attacked by the heat resisting amylase there is obtained in this stage where the presence of mono- and disaccharides is desired in respect of the colour and taste of the product, a strong formation of FlE~lACEMEN~ S~tEET
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In a preferred embodiment of the method with the view of preparing frozen products to be baked as Danish pastry products and the like, 0.05 to 0.1% by weight of Fungamyl MG 35000 and 0.1 to 0.2% by welght of AMG 300 MG are incorporated in the dough products, in both cases calculated on the weight of flour.
~ hese quantities of said two enzymes are about lO0 times larger than the quantities coming lnto con-sideration in the application hitherto practised of such enzymes in bakery articles. In said prior applica-tions use is made of Fungamyl MG 35000, an ~-amylase, to lower the fall number in strong flour. Said enzyme is produced by the mould fungus Aspergillus oryzae and decomposes the starch to dextrines and fermentable carbon hydrates. The enzyme AMG 300 is a glycoamylase extracted from the mould fungus Aspergillus niger decomposing starch and dextrines into glucose that participates in the brown-colouring Maillard-reactions.
Also with dough types to which it has hitherto been considered absolutely inevitable to add ferment-able carbon hydrates in the form of mono- or dlsacchar-ides, such as cold-rolled fat containing doughs for Danlsh pastry, croissant and the like, it is possible to obtain a satisfactory leavening of the dough pro-ducts at the ordinary rising temperature, i.e. 30 to37~C only with the addition of enzymes as stated. At this temperature fermentable carbon hydrates are obtained in a sufficient amount for yeast propagation and CO2-generation for rising the dough blank. When the leavening period has elapsed and the temperature is lowered to less than O~C the yeast activity will almost REPLACEMENTSHEEr . . . .. - ~: . . -~:: . ~ . ' .. .. ' . . ., . . . ~ ~ .
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WO91/01088 ~2966 PCT/DK90~00183 completely stop when the fermentable carbon hydrates have been consumed by the yeast, and that is the reason why the risen yeast product may be stored for a long time, e.g. at -18-C as explained above.
When said frozen yeast products are to be used they are put into the oven in-a froze~ condition, e.g.
at 220-C. The thawlng setting in in step with the baking, effects a decomposition of a limited proportion of the starch lnto fermenta~le sorts of sugar, e.g. by the enzyme Fungamyl, in particular in the temperature range from 27 to 55~C, ln which temperature range a proving ls being effected. At about 55~C the yeast cells die and the carbon hydrates, in particular glu-cose produced by the heat resisting enzyme, e.g. AMG, while the internal temperature of the product rises to 80 to 85~C and the starch partially gelatinizes, serve to impart to the final baXery product a suitable colour and taste.
The inventlon will now be illustrated;in detail by the following examples and examples of comparison.

A Danish pastry dough was prepared by mechanical kneading of the following ingredients:
Flour 2200 g Water 900 g Egg 500 g Yeast - - 175 g Fat ao g AMG 300 Mg 4 g "Fungamyl" R Mg 3500 2 g The dough was kneaded for four minutes, following which it rested for 15 minutes at 5~C.
For rolling in 1600 g margarine was used and the rolling was effected in an ordinary mannner, using F~EpLAcEMENTsHEET

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Wo9ltO1088 2 0 ~ 2 9 ~ ~CT/DKgo/00l83 three-doubled foldlng three times, thereby obtaining a total of 27 layers. After a rest period of 15 minutes and forming the dough, it was made to rise at 35~C for 40 minutes at a relative alr humidity of 80 to 85%, The dough was then subjected to freezing at -24~C.
To test the durability of the frozen leavened yeast dough products, test bakings were effected 7 days and 28 days, respectively, after the freezing.
The test bakings were carried out in an oven at 220~C for 12 minutes.
To determlne the change of volume by the baking, the volume was determined by the frozen dough blanks prior to baking and by the finished Danish pastry imme-diately after baking. The baking result was moreover visually and organoleptically evaluated.
lS The following results were obtained:
Volume:
Before baking After baking Increase After 7 days120 cm3 390 cm3 225%
After 28 days77 cm3 219 cm3 184%
In view of the fact that it has turned out in pract~ce that by this type of Danish pastry the best bakery result is obtAined when the volume increase by the baklng ranges from 100 to 300~, calculated on the volume of the dough blank when put into the oven, the above results are absolutely satisfactory and the obtained Danish pastry presented in all respects the same quality as Danish pastry produced from a fresh non-fro~en dough.

Exactly the same procedure was practised as in the above Example 1 with the variation that the two enzymes AMG 300 Mg and "Fungamyl" Mg 3500 were can-celled from the dough mixture which was instead mixed with 150 g sugar (corresponding to 6.8% of the flour weight) and 30 g salt.

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s The followlng results were obtalned:
Volume:
3efore baking After bakin~ Increase After ~7 days 190 cm3 300 cm3 58%
(2 pieces) (2 pieces) 10 After 28 days 102 cm3 159 cm3 56%

As it appears, the volume increase obtained by the baking was considerably smaller than was the case in the above Example 1 and considerably smaller than considered desirable. The resulting Danish pastry thus had not obtained the desired size and moreover pre-sented untisfactory organoleptical properties.

A dough for another similar bakery product, in Danish termed "sm0rbirkes" because it is sprinkled with poppy seeds, was prepared from the following ingre-dients:
Water 1350 g Yeast 250 g Egg 150 g Fat 200 g AMG 300 Mg 2 9 IlFungamyl'~ R Mg 3500 1 g Flour 2550 g .
The dough was kneaded ~Pch~nically for six mlnutes, following which it rested for 15 minutes at 5'C and was rolled ,with 920 g margarine to obtain a laminated dough cons~st~ng of 27 layers. Then the dough rested for 30 minutes and after forming the dough it ~EPLACEMENTSHEEt - - :: - ,: .: .
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WO91/01088 2 0 6 2 3 6 ~ PCT/DKgo/00183 was leavend at 34~C for 30 minutes at a relative airhumidlty of 85%
The freezing temperature was -30~C.
Test bakings were carried out after 7 days and after 28 days.
The following results were obtained by the -volume determlnations:
Volume:
Before baking After baking Increase 10 After 7 days 100 cm3 158 cm3 58%
After 21 days 140 cm3 200 cm3 43%
After 28 days 192 cm3 300 cm3 The final product was in all respects satisfac-tory and corresponded to commerial products prepared from non-frozen dough.

Exactly the same procedure was practised as in the above Example 2 with the variation that the two enzymes (AMG 300 Mg and "Fungamyl" Mg 3500) were can-celled from the dough mixture which was instead mixed with 75 g sugar (corresponding to 2.9% of the flour weight) and 30 g salt.
Test bakings were carried out after the frozen dough samples had been store for 3, 7, 21 and 28 days.
The following results were obtained:
volume:
Before baking After baking Increase After 3 days 120 cm3 200 cm3 67%
After 7 days 210 cm3 250 cm3 19%
- After 21 days 160 cm3 105 cm3 -3 After 28 days 222 cm3 213 cm3 - 5%

As it appears, the baking of the samples frozen for 21 and 28 days results in a volume decrease, f~EPlACEMENTSHEET

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~: : , ., WO91/01088 ~ 0;~ 2 9 6 l2 PCT/DK90/00183 meaning that the gluten components of the dough are extensively decomposed and the obtained baking result must be characterized as worthless, since it could not be ba~ed through and was pasty in its interlor whereas s the surface became strongly dark coloured.

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Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A method of producing a frozen, leavened laminated dough which is suitable for immediate baking when taken from the freezer comprising the steps of forming a dough essentially free of fermentable mono and disaccharides by mixing baking dough forming ingredients, other than fermentable mono and disaccharides, including four, fat, water, yeast and amylase, said amylase including an amylase component which remains active at temperatures above 60 degrees Centigrade, to form a baking dough to which fermentable mono and disaccharides have not been added, folding and rolling said dough to effect lamination thereof, leavening said dough and freezing the leavened dough, said amylase being added in an amount to generate sufficient fermentable saccharides under leavening conditions for yeast leavening of the dough and said component thereof which remains active above 60 degrees Centigrade being added in an amount sufficient to increase browning of the dough during baking thereof.

2. A method as in claim 1 and wherein said amylase includes fungal alpha amylase and the amount thereof added to the dough is at least 3500 SKB units per kilogram of flour.

3. A method as in claim 1 and wherein said amylase includes an amylase component which becomes inactive at temperatures above about 60 degrees Centigrade and the amount thereof added to the dough is between 0.05 and 0.1 percent by weight of the flour in the dough.

4. A method as in claim 3 and wherein said amylase is fungal amylase.

5. A method as in claim 4 and wherein said amylase component which becomes inactive above 60 degrees Centigrade is amylase produced by Aspergillus oryzae.

6. A method as in claim 5 and wherein the amylase component which remains active above 60 degrees Centigrade is amyloglucosidase and the amount of amyloglucosidase added is at least 60 AGU units per kilogram of flour.

7. A method of producing a frozen, leavened laminated dough which is suitable for immediate baking when taken from the freezer comprising the steps of forming a dough essentially free of fermentable mono and disaccharides by mixing baking dough forming ingredients, other than fermentable mono and disaccharides, including flour, fat and water, yeast, alpha amylase and amyloglucosidase to form a dough to which fermentable mono and disaccharides have not been added, folding and rolling said dough to effect lamination thereof, leavening said dough and freezing the leavened dough, said alpha amylase being added in an amount sufficient to generate sufficient fermentable saccharides under leavening conditions for yeast leavening of the dough and said amyloglucosidase being added in an amount sufficient to increase browning of the dough during baking thereof.

8. A method as in claim 7 and wherein said amylase is a fungal amylase and the amount thereof added to the dough is at least 3500 SKB units per kilogram of flour and the amount of amyloglucosidase added to the dough is at least 60 AGU units per kilogram of flour.

9. A method as in claim 8 and wherein said amyloglucosidase is amyloglucosidase that becomes inactive at temperatures above about 85 degrees Centigrade.

10. A method as in claim 9 and wherein said amyloglucosidase is a fungal amyloglucosidase and the amount thereof added to the dough is between 0.1 and 0.2 percent by weight of the flour in the dough.

11. A method as in claim 10 and wherein said amyloglucosidase is produced by Aspergillus niger.

12. A frozen, dough product suitable for immediate baking when taken from the freezer comprising a yeast-leavened, laminated dough essentially free of fermentable mono-and disaccharides and comprised of flour, fat, water and amylase in an amount sufficient to generate sufficient fermentable saccharides, under leavening conditions for yeast leavening thereof, said amylase including an amylase component which remains active at temperatures above 60 degrees Centigrade, said component being present in an amount which will increase browning of the dough during baking thereof.

13. A product as in claim 12 and wherein the amylase includes an amylase component which becomes inactive at temperatures above about 60 degrees Centigrade in the amount of at least 3500 SKB units per kilogram of flour.

14. A product as in claim 13 and wherein said amylase component which becomes inactive at temperatures above about 60 degrees Centigrade is alpha amylase.

15. A product as in claim 14 and wherein said alpha amylase is a fungal amylase produced by Aspergillus oryzae.

16. A product as in claim 12 and wherein said amylase component which remains active at temperatures above 60 degrees Centigrade is amyloglucosidase that becomes inactive at temperatures above about 85 degrees Centigrade, said amyloglucosidase being incorporated in said dough in an amount of at least 60 SKB units per kilogram of flour.

17. A product as in claim 16 and wherein said amyloglucosidase is a fungal amyloglucosidase.

18. A product as in claim 17 and wherein said amyloglucosidase is produced by Aspergillus niger.

19. A product as in claim 12 and wherein said product is a frozen Danish pastry dough product.

20. A product as in claim 12 and wherein said product is a frozen croissant dough product.

21. A pastry dough product suitable for frozen storage for baking at a later time comprising a laminated and shaped dough essentially free of fermentable mono-and disaccharides and comprised of flour, fat, water, yeast in an amount sufficient to leaven the dough and amylase in an amount sufficient to generate sufficient fermentable saccharides under leavening conditions for yeast leavening of the dough, said amylase including amyloglucosidase present in an amount sufficient to increase browning of the dough during baking thereof.

22. A pastry dough product as in claim 21 and wherein said amylase comprises fungal alpha amylase produced by Aspergillus oryzae.

23. A method of producing a frozen, leavened, laminated dough which is suitable for immediate baking when taken from the freezer comprising the steps of forming a dough essentially free of fermentable mono and disaccharides by mixing baking dough forming ingredients, other than fermentable mono and disaccharides, including flour, fat, water, yeast and amylase, to form a baking dough to which fermentable mono and disaccharides have not been added, folding and rolling said dough to effect lamination thereof, leavening said dough and freezing the leavened dough, said amylase being added in an amount to generate sufficient fermentable saccharides under leavening conditions for yeast leavening of the dough, wherein said amylase includes amyloglucosidase present in an amount sufficient to increase browning of the dough during baking thereof.

24. A method as in claim 23 and wherein said amylase is a fungal alpha amylase and the amount thereof added to the dough is at least 3500 SKB units per kilogram of flour and including the steps, prior to leavening, of cold rolling and folding said dough to form a laminated dough.

25. A frozen dough product suitable for immediate baking when taken from the freezer comprising a yeast-leavened, laminated dough essentially free of fermentable mono and disaccharides and comprised of flour, fat, water, yeast and amylase in an amount sufficient to generate sufficient fermentable saccharides under leavening conditions for yeast leavening of the dough, wherein said amylase includes amyloglucosidase present in an amount sufficient to increase browning of the dough during baking thereof.

26. A product as in claim 25 and wherein said amylase comprises a fungal alpha amylase produced by Aspergillus oryzae.

27. A product as in claim 26 and wherein said product is a frozen Danish pastry dough product.

28. A product as in claim 26 and wherein said product is a frozen croissant dough product.